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By C Gormley, G Lane, J Kwak, A Hopkins

Complex processing plants present a myriad of safety issues to the design engineer. The extent to which the design engineer manages to lay the foundations for a safe plant ultimately sets the stage for life long safety performance. Industry traditionally measures engineering safety performance by indicators such as Lost Time Injuries, Restricted Work Case Injuries, Overall Incident Frequency Rates, etc. While these measures are useful indicators of performance for the construction, commissioning and operations phase of a project, they do not necessarily drive the most appropriate behaviours for Safe Plant Design. Achieving an inherently safe design requires a diligent focus on low frequency, high consequence events. First and foremost the engineering team needs to have a design culture and methodology which leads to a plant which is as close as possible to being inherently safe. Such a culture might come from an organisation that has æmindfulnessÆ about safety, and which is nurturing a culture where warning signs are recognised and addressed. This paper explores the development of mindfulness and warning signs in design.

Jan 1, 2004

By J Lim, M Powell, P J. Scales

The current philosophy employed in the design of mineral processing plants effectively involves bolting together segmented unit operations both chosen and optimised from a product-centric perspective. In this context, integration of water saving technologies at an overall plant level becomes difficult and often only local water efficiency improvements are feasible. In general only limited benefit can be obtained from such add-on solutions. It is therefore proposed that to obtain significant savings in water consumption and reductions in the volume of discharged contaminated water in the mining process, the entire process along the mining and mineral processing chain should be addressed This paper explores aspects of the processes that may be modified to provide an integrated and combined step change saving in water consumption. It is also apparent from this study that taking a more holistic view of the process can provide significant benefits in energy savings and total cost of production, providing the potential of a substantial win-win outcome.

Jan 1, 2009

Leadership challenges for mine management over the next decade will be primarily about doing more with less labour. This will require a greater focus on people leadership and management, reducing uncertainty by evening out employment peaks and troughs, understanding and addressing our demographic destiny and its implications whilst identifying and holding onto our mission critical employees, managing creativity and accepting diversity whilst providing flexibility in employment for work-life balance. Greater emphasis will also be required on the non-technical social skills of complex interactions with community and education providers and finally a greater emphasis on forecasting and planning for the provision of future skills needs. Skills needs will become an ever increasing priority in risk management as retention starts with attraction and remember: SATISFACTION = REALITY                                EXPECTATIONS These are the challenges and opportunities for leadership and mine management of the 21st century to assist in better meeting and maintaining our human resources needs and thus contributing to the sustainability of the sector in Australasia.

Jan 1, 2006

Capital expenditure on sampling and blending is often very difficult to justify. The costs are easy to estimate but the benefits likely to be obtained by constructing good sampling and blending facilities are generally difficult to estimate. For instance, improving blending of the ore feed to a smelter would improve throughput, yield and controllability ... but by how much? Similarly, better sampling would allow processing conditions to be dynamically adjusted and would improve extraction ... but by how much? Predicting benefits often requires the use of simulation models which carefully distinguish between true grades, predicted grades and observed grades. The parameters of these simulation models must often be estimated from rather inadequate information. These difficulties are illustrated using three scenarios.

Jan 1, 2005

By the 1990's Australia could be the largest coal exporter in the world and one of the few industrialised countries potentially able to supply the shortfall in its domestic oil requirements by utilizing its oil shale and coal resources to manufacture synthetic oil. The major challenge to both industry and government in implementing the new role for Australia will be to ensure that their actions and policies enable the timely mobilization of resources needed to meet the potential demand for energy, both domestic and overseas. Australia's potential for coal production and exports and for the production of oil from shale and coal are discussed and the potential constraints to development Examined.

Jan 1, 1981

By M N. Ingham

X-ray fluorescence (XRF) spectrometry has always been considered to be a comparative method of analysis. Reference materials are required to calibrate the analytical system. This paper describes the use of a set of æsyntheticÆ oxide standards, made from commercially available high purity compounds, to calibrate a spectrometer for 21 major and minor oxides. The spectrometer software uses simple methods of background correction, and a fundamental parameter method of matrix correction. Sample preparation is by fusion in 66 per cent lithium tetraborate, 34 per cent lithium metaborate. The use of synthetic standards, made from traceable compounds, brings XRF significantly closer to being a primary rather than a comparative method. Reference materials were used to validate the method described and examples of accuracy for major constituents are given using ores and other minerals. This method has successfully been used to analyse a wide variety of minerals and ores, as validation data shows. A titanium process example clearly shows the benefits of highest accuracy analysis.

Jan 1, 2008

Most mining projects will involve some level of financial markets price risk. This is because commodities are generally traded in $US. The project will also incur costs in $A and if based in Australia will seek to generate a return in Australian dollars. Therefore the project faces commodity, foreign exchange and interest rates risk. As a business you may wish to maintain these risks within your business. However if the project requires financing to be provided then the financiers will want to ensure that there is a level of certainty attached to the cash flows to support the debt repayments. This is achieved by hedging the financial market risks. Traditionally the hedging process has been based on underlying assumptions within project models, which incorporate views on the direction of the underlying price risk. These views can be formed in an ad hoc manner. Gathering information from a variety of sources including economic forecasting and modelling, technical analysis, seeking market expert views. However, given the historical accuracy of such forecasts locking into long-term fixed hedging arrangements can create an inflexible environment that can restrict the opportunity to benefit from the underlying volatility of financial markets.

Jan 1, 2003

The concept of "profit" is implicit in the definition of an ore reserve. It is suggested that the flexible concept "economic" is more appropriate. This allows different economic considerations to be taken to account when determining what is ore at the feasibility study stage; during actual mining production; before mine closure; and from the viewpoint of the national economy. Economic factors which are highly variable, and largely beyond a mining enterprise's control, affect the economic exploitation of a mineral resource. Major economic factors include: metal prices; operating costs; the cost of original and replacement capital equipment; the cost of capital; taxation and royalties; inflation; exchange rates and the state of the world economy. The paper suggests why a careful quantification of the average value, trend, and variation from the trend of major economic factors should be made and how this will lead to a better definition of ore reserves. The paper also discusses the necessity of reappraising economic factors during the life of a mine in order to maximise the economic surplus and to minimise the wastage of natural, economic and human resources employed in mining.

Jan 1, 1979

By Thorburn D

This paper reviews the history of environmental assessment in New Zealand with reference to mineral developments. Emphasis is given to larger more controversial projects particularly metal mines. The changing role and application of the Environmental Protection and Enhancement Procedures is examined in the context of changes in the government's environmental administration and the response of the Ministry of Energy's resource allocation group. Conclusions are drawn on the effectiveness of the present environmental assessment activities and on the allocation of administration of priorities in the Ministry. The Ministry of Energy has effectively ceased to exist.

Jan 1, 1990

Mount Gibson Iron Limited (æMount Gibson IronÆ) has made the difficult transition from a privately owned company with an iron resource to a publicly listed company owning and operating a profitable iron ore mine in the mid-west of Western Australia. The development of the company is described with particular emphasis on the Tallering Peak operations, resources, associated infrastructure and logistical arrangements; the Mt Gibson hematite and magnetite resources and the proposals to develop the magnetite resource as part of an integrated project through to iron pellet production. The concept of tailoring the relatively small ship capacity of the outturn port of Geraldton to appropriately sized inturn ports in China to allow direct delivery of product is discussed. The companyÆs philosophy of building shareholder value by progressive development of its relatively modest resources (compared with the Pilbara) is discussed. In pursuit of long-term business success Mount Gibson Iron has formed symbiotic relationships with strong business partners whose aims and objectives mirror or complement those of Mount Gibson Iron.

Jan 1, 2005

From December 1994 to November 1997 Odin MiningÆs Estero Hondo alluvial gold mine in western Ecuador washed almost 3.2 million bank cubic metres of gravel to produce just over 2600 kilograms of pure gold at a recovered grade of about 0.8 grams per bank cubic metre. The operation was a simple open pit. Draglines stripped the overburden, backhoes mined the gravel, and trucks transported the ore to a stationary, gravity-based wash plant for processing. At start-up the planned throughput was 55 000 bank cubic metres/month, but a year later this had been increased to 100 000 bank cubic metres/month. From April 1993 to July 1997 a total of 440 churn drill holes and 15 pits were sunk to test the property. The methods used to prepare the resource and reserve estimates from the raw field data are described, and seven sets of completed estimates are used to track the evolution of the projectÆs resource/reserve base through the exploration, feasibility and production stages.

Jan 1, 2003

I am honoured, deeply honoured, that so distinguished a group has assembled to acknowledge the signifi- cance of the work of my Melbourne flotation research laboratory, to review progress since Principles of Flotation (Wark, 1938) was published, to highlight the present state of knowledge, and to point the way for future research. The flotation research which began in 1929 was sponsored by a group of mining companies2 at the instigation of Harry Hey of the Electrolytic Zinc Company of Australasia Limited. There were never more than three of us work- ing in rather cramped conditions in a laboratory made available by the Department of Chemistry at the Uni- versity of Melbourne, but what we lacked in space was more than offset by a freedom unparalleled in indus- trial research in Australia at that time. I pay special tribute to my first colleague, Alwyn Cox; to my wife who worked with us for several years; and to Keith Sutherland who followed Cox in 1936. They were my sole colleagues up to 1938 when Principles of Flo- tation (Wark, 1938) was published.

Jan 1, 1984

By Morrison RD, Simmons CJ

A bewildering array of process control instrumentation is currently available for mineral processing plants. For sequencing control, special purpose microprocessors or the process control computer can be used. Where continuous control is required, then the choice is between pneumatic controllers, electronic controllers, shared display micro- processor systems and direct digital control. The benefits of each system are discussed and the advantages of using direct digital control in mineral processing plants are outlined. The factors which need to be considered when selecting control systems for new plants are listed. Instrumentation systems designed by Fluor Australia are used as case studies to illustrate the selection process. For established plants, conversion to direct digital can be advantageous, and case studies are given. However, replacement of existing systems requires justification based on a productivity improvement which will allow the control equipment to be paid for within a specific time period. Productivity improve- ments maybe assessed in terms of increased

Jan 1, 1978

By Robson L. C

The developing countries whether they be in Africa, Asia or the Pacific, are a potentially vast market for the technologies of the more developed countries.Conducting business in the less developed countries however requires a keen understanding of their culture. A keystone of the culture of the Pacific Island Nations is kinship with the land. Without an appreciation of the implications of the land rights debate, a business venture into these countries is likely to be delayed or even doomed to failure.The European heritage, with its notions of private ownership of land, have frequently been a stumbling block to a proper understanding of the concepts of customary lands. According to our laws, ownership of land confers a number of definite rights: principally the right to use the land, the right to exclude others from its use, the right to transfer it and the right to receivF income from the property independent of use.

Jan 1, 1990

By Richards AG

The stimulus of major capital expenditure in establishing open cut coal mining operations in the Hunter Valley led Coal & Allied Industries to look to a computer based information system as a tool to assist mine management in day to day operating decisions, as well as to provide a base of comparative data to help in long term equipment procurement decisions. The mine information system was conceived as an integrated set of three subsystems; costing, production recording, and maintenance. The maintenance management features of the system are closely keyed to a policy of preventive maintenance and maintenance costing based on user specified parameters. Central to this policy is the maintenance work order, which may be created and updated directly via interactive procedures at visual display terminals. The, system was designed for on-line processing in a multi-mine shared operating environment. Each mine controls its own data capture, and most other processing functions directly from terminals. The system is currently operational on the Combined Group Services Pty Ltd FACOM M150 computer, located in Newcastle, NSW.

Jan 1, 1983

By A Kyllo a, D R. Swinbourne

Electric arc furnace (EAF) dusts contain significant quantities of zinc, found almost entirely as either zinc oxide or zinc ferrite. The dust has been classified as a hazardous waste due to the relative high lead, cadmium and hexavalent chromium contents. It is important that environmentally acceptable processes be developed to treat this waste. One possible process involves reacting the zinc compounds in the dust with metallic iron, thus avoiding zinc vapour reoxidation by CO2 as occurs in carbon reduction processes. It consists of two stages where the first is the reduction of iron oxides to iron and the second the reduction of zinc oxide to zinc vapour by the iron. In this work the effects of operating variables such as temperature, CO/CO2 ratio and pressure on the recovery of zinc from an industrial EAF dust obtained from the Smorgon Steel Mill were investigated. Zinc recoveries in the second stage were found to approach 100 per cent at 1000oC after about four hours in nitrogen but within 40 minutes if a low vacuum was used.

Jan 1, 2000

Since 1960, the Dongchuan Copper Mining Bureau, Yunnan Province, China, has treated copper oxidised ores by sulphidisation - flotation technique only to recover copper. In order to improve the metallurgical performances and economics of flotation, extensive development work has been carried out during the past 30 years: several specific flotation flowsheets have evolved from the originally selected `stage - grinding and stage - flotation' flowsheet to suit various ores; the overall grinding size of the ores has been increased from 80 per cent - 200 mesh to 90 per cent - 200 mesh, resulting in significant increase in copper recovery; the substitution of CaS for NazS proved to be successful in sulphidisation of copper oxidised minerals, and also in avoiding the depressing effect of Na2S on copper sulphide minerals; the application of a number of activators of copper oxidised minerals, especially ethylene diamine phosphate, has considerably improved the flotation performance and decreased the consumptions of other reagents. Finally, the combined use of sodium hydroximate with butyl xanthate has been shown to be effective in enhancing the floatability of both copper oxidised and sulphide minerals.

Jan 1, 1993

By Dobias B

A new separation method based on a combination of coagulation and colum flotation was used to treat fine sphalerite in the range 90 per cent - 15 pm with a relative high superfical gas velocity and a thick froth layer. Minerals studied include sphalerite, calcite, kaolinite and baryte. A new developed sedimentometer was used for sedimentation analysis to characterise hetercoagulation of mixture and coagulation after addition of active ions or reagents. A comparison between use of selective frother and depressant (SHMP) was made to deactivate activated minerals. Selectivity of frother for sphalerite was found in flotation test. The depression function of Flotanol for activated minerals was confirmed in sedimentation alalysis. The use of small quantities of HPAM can improve the flotation of fine sized sphalerite particle and reduce recovery of activated gangue minerals in the neutral or alkaline pulp. A satisfactory separation of fine sphalerite from its gangue was achieved by using alkylpolyglycolether (Flotanol) and copolymer polyacrylamide (HPAM hydrolysed polyacrylamide) as frothing and flocculating agents Respectively.

Jan 1, 1993

By M Bezzina

In 1995 Standards Australia International Limited æSAIÆ published a risk management standard titled AS/NZS 4360 Risk Management. It was the first such standard published by a recognised formal standards body anywhere in the world and it put Australia at the leading edge of the risk management discipline. Many Australian and international organisations have utilised the risk management standard and it is one of SAIÆs most important and popular standards. Since its publication in 1995, the risk management standard has gone through a major revision in 1999 and is currently undergoing another such review, which is due for completion in 2004. This paper will chart the application of the standard within certain key organisations since its inception in 1995. A brief overview of the methodology behind AS/NZS 4360 will be presented as well as an overview of supporting and related standards. It is prudent to base risk management and other management system issues on existing and tested standards rather than creating new proprietary approaches. Examples of areas in which the risk management standard might be applied in the mining industry are given, subject to the specific operations of each company: technical, commercial, environmental, informational, and safety and regulatory.

Jan 1, 2003

Economic and environmental pressures are shifting the world balance of titanium dioxide production away from sulphate based. manufacture towards the more cost effective and cleaner chloride route. In the chloride process for titanium dioxide pigment manufacture, TiOz and other metal oxides in the feed ore are reacted at high temperature with chlorine in the presence of carbon. These gases are cooled after they leave the reaction zone, upon which solid contaminants precipitate and are substantially removed. The liquid titanium tetrachloride is purified by distillation before again being vaporised and interacting with hot oxygen to form pigmentary titanium dioxide and regenerate chlorine for recycle. The base pigment is wet milled, surface treated (by coating with hydrous oxides of silica, alumina and others) and redispersed before packaging. Optical properties of TiO2 pigments are reviewed and the role of refractive index and particle size explained in brief. Pigment related factors affecting the opacity, colour, undertone, gloss and durability of coatings are examined with respect to manufacturing requirements. The superior performance of chloride based pigments is briefly reviewed.

Jan 1, 1991